Diamond-tiled workpiece for durable surfaces

ABSTRACT

A method for producing a durable, non-stick, diamond-tiled implement and the diamond-tiled implement thereby produced. Diamond particles are distributed on a surface of a workpiece containing a ceramic binder. The ceramic binder on the surface of the workpiece is heated to above its glass temperature to fuse the diamond particles in and onto the workpiece. The workpiece is then cooled so that the diamond particles are bonded to and at least partially embedded in the ceramic binder at the surface of the workpiece to produce durable, non-stick, diamond-tiled implements including cookware, bakeware, hot-presses, ski surfaces, skid surfaces, marine articles, and mechanical polishing wheels. Other implements of this invention utilize a high diamond content to produce thermally conducting and electrically insulating coatings for heat spreaders, or conversely, heaters.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority under 35 USC §119 to U.S. provisionalpatent application No. 60/090,700 filed Jun. 24, 1998, the entirecontents of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to both a method for producing a durablenon-stick workpiece article and the article of manufacture produced bythe inventive method.

More particularly, this invention relates to the consolidation ofdiamond powder to a binder coating the surface of a metal substrate.

2. Discussion of the Background

Non-stick articles are quite prevalent in today's world.Polytetrafluoroethylene (TEFLON) is one material that is widely-used formany non-stick applications. Besides TEFLON, silicone coatings are alsoused in non-stick applications. Both TEFLON and silicone, however, arevery soft materials and suffer from abrasive wear which shortens thelifetime of the non-stick article. In addition, TEFLON and silicone haverelatively low temperature ratings. For example, when a TEFLON coatingbecomes too hot, the TEFLON begins to decompose spontaneously.

Porcelain enameling is a commercial, industrial scale technology whichis used to coat a variety of objects of various sizes and shapes.Porcelain by itself can provide a smooth, stick resistant surface. Theuses of porcelain enameling include glass-lined water heater tanks,cookware, kitchen appliances, barbeques, heat exchangers, architecturalpanels, decorative jewelry, road signs, and silo panels used for grainstorage. Porcelain enamel is used as a protective coating on a varietyof metals and is used as a glazing on glassware and whiteware.

The porcelain coating industry for years has developed appropriateenamels for various base substrate materials. The porcelain coatingindustry relies heavily on experiential data to obtain the best enamelcoating and adhesion to the wide variety of metals which it coats. Themethods used to coat aluminum with porcelain are different than themethods used to coat steel with porcelain. Likewise, methods for coatinglow-carbon steel are different than methods for coating cast iron, andmethods for coating copper and gold are different from methods forcoating steel formulas. Methods of applying a porcelain coat to metaltypically include the application of ground coats (also called basecoats). Also, these methods typically contain top coats which willcontrol the background color and finish of the coated workpiece;however, porcelain surfaces are prone to scratching, particularly whenbeing cleaned with an abrasive.

Diamond, due to its low coefficient of friction and high hardness, is anexcellent non-stick material: however, high-pressure, high-temperature(HPHT) synthesis of diamond on common metal and glass surfaces is notpossible because the temperatures attained during HPHT synthesis exceedthe melting points of many common metals and glasses. Further, HPHTsynthesis is only practical for limited areas because of the highpressures (100 GPa) required for HPHT synthesis.

Diamond is known to have many superior properties when compared to othermaterials. These properties make diamond a viable candidate forapplications where the surface of a material is exposed to mechanical,chemical, or physical wear. For example, diamond is known to have a lowcoefficient of friction and superior hardness. As such, diamond would bean ideal candidate for non-stick surfaces and could potentially replaceTEFLON coatings on cooking surfaces. Diamond is also known to have lowsputter yield and is extremely chemically resistant. As such, diamondwould be an excellent protective coating on electrodes and surfacesexposed to plasmas and ion bombardment. Diamond's superior chemicalresistance would make it an ideal container coating in applicationswhere leaching of the wall materials by the chemical effluent eitherproduces contamination of the process stream or produces a long-termreliability problem for the storage of the effluent.

Unfortunately, the application of diamond directly to typical surfacespresents high technical and cost barriers which have either made diamondapplication impossible or extremely costly. On the one hand, highpressure synthesis is used to produce nearly 100 tons of synthetic gritper year at a fairly cheap cost per carat (current selling prices areunder $1.00/carat). The high temperatures and pressures required forhigh pressure synthesis of diamond are not compatible with coatingdiamond directly onto common materials such as steels, aluminum, orglassy materials. On the other hand, chemical vapor deposition (CVD) ofdiamond is a viable technical approach for the formation of diamond onthese common materials. Indeed, deposition on these materials directlyor with the use of surface pre-treatments or inter-layers has beendemonstrated. U.S. Pat. No. 5,686,152 to Johnson et. al. teaches amethod using electrical bias to directly nucleate and grow diamond filmson substrates using a CVD approach wherein an electrical bias is appliedto the substrate to enhance nucleation. Unfortunately, the high cost ofCVD diamond ($5-$20/carat) restricts this approach.

Chemical vapor deposition (CVD) of diamond can be conducted atatmospheric pressures. However, industrial economies of scale cannot berealized with the manufacturing equipment currently available to producelarge area CVD coatings. As a result, large area CVD coatings of diamondare too costly for manufacturers to feasibly employ.

U.S. Pat. No. 3,338,732 to Holcomb teaches a method of embedding silicaparticles in a porcelain enamel to give the porcelain enamel a roughappearance. A porcelain ground coat is applied to a metal substrate andheated so that the porcelain ground coat becomes fused to the metalsubstrate. Next, a wet cover coat of porcelain enamel is applied to theground coat by spraying or dipping. While the cover coat is still wet,silica particles are sprinkled over the wet cover coat so that thesilica particles become partially embedded in the wet cover coat. Thecover coat is heated to fuse the cover coat to the ground coat and tofuse the silica particles to the cover coat. Next, a top coat is appliedto the exposed portions of the cover coat and the silica particles. Thetop coat is then heated to fuse the top coat to the exposed portions ofthe cover coat and the silica particles. The resulting product has arough surface on which there is no exposed silica.

U.S. Pat. No. 3,650,714 to Farkas discloses a method of coating singlediamond chips with titanium or zirconium. The diamond chips arerelatively large, having a mesh size of 200-250. Farkas teachesoverlaying the titanium-coated diamonds with a second layer of nickel orcopper or both nickel and copper, placing the coated diamonds on a steelsubstrate, and covering the coated diamonds with powdered ceramic. Thepowdered ceramic is then vitrified to secure the coated diamonds to thesteel substrate. Since the diamond chips are coated, no portion of thesurface of the diamonds is exposed and the diamonds are not bonded tothe ceramic.

U.S. Pat. No. 4,749,594 to Malikowski et al. discloses a method forcoating ceramic surfaces with hard substances. The method includes thesteps of coating a metal or ceramic substrate with a metal powder, thespraying the substrate with a diamond powder, and heating the coatedsubstrate to between 900 and 1200° C. The heating step causes the metalpowder to melt. The molten metal wets both the diamond particles and thesubstrate. When the melted metal is cooled, diamond particles from thediamond powder are integrally bonded to the substrate by the formedsolder (hardened metal). The step of heating the coated substrate isperformed in a high purity argon atmosphere or at sub-atmosphericpressure to prevent reactions between the active component of the metalpowder and the remaining gases. In a first example, the invention ispracticed with 40-50 micron diamond powder; in a second example, theinvention is practiced with 60-80 micron diamond powder.

U.S. Pat. Nos. 5,164,220 and 5,227,940 to Caballero disclose a method ofcoating a metal substrate with treated diamond particles. Chemicalplasma deposition is performed to grow an SiC crystal layer on thediamonds. Caballero discloses several different techniques for coatingthe metal substrate with the treated diamond particles. These techniquesinclude sintering, brazing, and electroplating.

U.S. Pat. No. 5,453,303 to Holcombe et al. teaches a method ofdepositing a full diamond coating on a substrate. A powder mixture ofglassy carbon and diamond particles is heated and impinged upon thesubstrate at high velocity. Upon impact with the substrate, the glassycarbon is phase transformed to diamond. The diamond particles promotethe phase transformation of the glassy carbon to diamond. Similarly,U.S. Pat. No. 5,635,254 to Holcombe et al. teaches a method ofdepositing a layer of diamond or diamond-like material on a substrate.In one embodiment, a plasma gas stream heats and propels a mixture ofglassy carbon and diamond particles onto the substrate. The mixture isthen quenched on the surface of the substrate to produce a diamondcoating.

SUMMARY OF INVENTION

Accordingly, it is an object of the present invention to take advantageof the durability and non-stick characteristics of diamond in providinga novel durable, non-stick workpiece at relatively low cost.

It is also an object of the present invention to provide a novel methodof manufacturing a durable, non-stick workpiece in which durability andnon-stick characteristics are achieved by use of diamond.

It is also an object of the present invention to provide a method forproducing a diamond-tiled, durable, non-stick surface on a variety ofobjects having various, shapes, sizes and surface areas.

It is also an object of the present invention to provide an article ofmanufacture having a durable, non-stick, diamond-tiled surface.

These and other objects of the present invention are achieved accordingto a novel method of producing a diamond coated implement wherein aworkpiece having a surface including a ceramic binder is provided.Diamond particles are distributed on the surface of a workpiece. Thesurface is heated to melt at least a portion of the ceramic binder. Thenthe surface of the workpiece is cooled so that a portion of the diamondparticles remain bonded to, and embedded in, the ceramic binder at anexposed surface of the workpiece to produce a diamond-tiled coatinglayer. Optionally, a ceramic binder may be distributed on the workpieceas a dry powder frit, eliminating the need to provide a workpiece havinga surface that includes a ceramic binder.

According to the novel method of the present invention, a durable,non-stick, diamond-tiled surface coating is provided on the workpiece(i.e. the surface is diamond-tiled).

The inclusion of diamond powders in the surface of the workpiece causesthe durability of the workpiece to surpass the durability ofconventional workpieces that are coated with TEFLON or with porcelainalone. The diamond coated surface is resilient to high temperatures andresistant to abrasion.

BRIEF DESCRIPTION OF DRAWINGS

A more complete appreciation of the invention will be obtained as thesame becomes better understood by reference to the following detaileddescription when considered in connection with the accompanyingdrawings, wherein:

FIG. 1 is a flowchart describing the method of forming a diamond-tiledsurface in accordance with the teachings of the present invention;

FIGS. 2(a) through 2(e) are sectional views of a workpiece at variousprocessing steps when using a fired porcelain ceramic surface as thestarting workpiece;

FIGS. 3(a) through 3(e) are sectional views of a workpiece at variousprocessing steps when using porcelain frit and diamond powder to coat aporcelain ceramic workpiece; and

FIGS. 4(a) through 4(e) are sectional views of a workpiece at variousprocessing steps when using an un-fired porcelain ceramic surface as thestarting workpiece.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings, wherein like reference numerals designateidentical or corresponding parts throughout the several views, FIG. 1 isa flow chart describing a method of providing a workpiece with adiamond-tiled surface in accordance with the teachings of the presentinvention.

In step S1, diamond crystallites or a mixture of diamond crystallitesand porcelain frit are distributed evenly over the surface of theworkpiece. The porcelain surface can be provided on the workpiece usingany appropriate technique known in the porcelain enamel industry.Alternatively, a workpiece that already has a porcelain surface can beused.

Any suitable technique may be used to distribute the diamondcrystallites or mixture of diamond crystallites and porcelain frit overthe surface of the workpiece. In one embodiment, a suspension of diamondpowder is provided in an aerosol medium. The aerosol is sprayed upon theporcelain surface whereupon the solvent evaporates, leaving behind thedry diamond powder as a top coat. It is important for cost control thatthe aerosol method not use excess diamond powder which will merely addundue cost to the coating process. The porcelain industry currently isdeveloping solvent-less electrostatic spray techniques used quitecommonly now in the paint industry to restrict volatile organic compound(VOC) emissions. These techniques are very efficient with little paintpigment loss. These electrostatic spray techniques may be used toprovide a very precise and controlled method for uniformly dispensingdiamond powder onto the porcelain surface.

These simple spray techniques lend themselves to patterning of thediamond on the workpiece surfaces.

Any diamond powder can be used to provide the diamond crystallites usedfor the invention. For applications as a diamond-tiled cookware surface,the powder is graded to a size that is less than 5 microns in diameter.That is, the powder is sieved such that most, if not all, of theparticles having a maximum diameter of more than 5 microns are removed.In the context of the present invention, the “maximum dimension.” the“particle size,” and the “powder size” of the diamond particles allrefer to the size to which diamond powder has been graded.

Powder sizes greater than 5 microns in diameter will result in thediamond-coated surface having a rough surface finish. This will requireadditional measures to finish the coated surface. By using powder sizeless than 5 microns in diameter, the surface roughness will beapproximate to standard industrial finishes. Smaller powder size willalso help in suspension of the powder and its dispersion over theworkpiece surface. For other applications, the crystallite size chosenwill be dependent on nature of the application. In fluid handlingapplications, the crystallite size will determine the surface roughnessand thus the viscosity of the fluid along the container boundary. Here,a rough surface is desirable. It creates slip planes in the fluid whichreduces the frictional drag from the walls. If the diamond coatedsurface is applied to a polishing or finishing wheel, small powder sizespermit polishing operations while very small powder sizes permitfinishing operations. If the diamond coated surface is applied to alapping wheel, larger powder sizes are desirable for performing grindingand lapping operations.

Diamonds of any size may be used to implement the teachings of thepresent invention. For example, large diamond particles (e.g., diamondparticles having a maximum dimension greater than 50 microns) may beused in decorative applications including the adornment of chinaware orjewelry.

In step S2, the workpiece having the diamond-tiled coating is fired toabove the glass temperature of the particular porcelain enamel used. Foraluminum-based porcelain coated materials, the glass temperature of theporcelain is typically ranges from 500 to 600° C. For steel-basedporcelain coated materials, the glass temperature of the porcelain istypically ranges from 650 to 850° C. At these temperatures, theporcelain glass surface becomes fluid. The diamond powder, which stillremains far below its melting temperature, penetrates the fluid surfaceof the porcelain.

In some applications, it is desirable to spray dry diamond powderdirectly onto the porcelain glass while in the high-temperature fluidstate, i.e., after the porcelain has been heated. When the porcelain isheated before the distribution of diamond powder, it may be desirable toheat the porcelain again after the distribution of diamond particles. Ifan aerosol medium is sprayed directly onto fluid porcelain glass, theaerosol medium is preferably non-explosive to eliminate the risk ofexplosion.

Diamond attachment to the porcelain surface occurs as a result ofchemical and mechanical bonding between the diamond crystallites and theporcelain enamel glass. During the high-temperature firing process, itis observed that the fluid porcelain glass wets the diamond surface.Wetting of one surface by another is evidence of the formation of achemical bond at the interface between the two materials (the amorphousglass and the crystalline diamond). Furthermore, the expansioncoefficient difference between diamond (1 ppm) and the porcelain glass(5-10 ppm) results in compression forces on each of the diamond powdercrystallites as the porcelain surface cools below the glass temperatureof the porcelain (approximately 550° C. depending on the type ofporcelain). These forces serve to embed the diamond crystallites ontothe porcelain surface under a compressive stress which adds a mechanicalbond.

Once the diamond surface penetration is complete, the workpiece iscooled to below the glass temperature of the porcelain in step S3 sothat the porcelain hardens. As the porcelain hardens, compressivestresses develop on the diamond crystallites which serve to fix thediamond crystallites onto the porcelain surface. The cooling ramp toroom temperature is best dictated by procedures and practices used inthe porcelain industry to prevent spalling of the porcelain enamelcoatings.

Residual un-reacted crystallites are removed from the surface in stepS4. Preferably, water with an abrasive action is used in step S4 toremove the residual powder. The residual diamond crystallites go intosuspension in the water and are rinsed from the surface. The water maybe captured and evaporated, leaving behind the un-reacted diamondcrystallites. Thus, the un-reacted crystallites are reclaimed for futureapplication.

Diamond surface exposure must be insured if the inherent properties ofthe diamond are to be realized. For many applications, it is desirableto have a diamond surface exposure percentage that maximizes thelifetime of the workpiece. The diamond surface exposure percentagedepends, in part, on the firing conditions and the particle size of thediamond crystallites. For example, the use of extremely coarse powder(e.g., particles having a maximum diameter of at least 10 microns) andshort firing times will not permit complete encapsulation of the diamondpowder by the porcelain enamel glass. On the other hand, the use of veryfine diamond powder (e.g., particles having a maximum diameter less thanor equal to 0.1 microns) and long firing times, e.g., four minutes, mayresult in complete encapsulation of the diamond crystallites in theporcelain glass. In this case, post-firing processes such as mechanicalpolishing, chemical etching, chemi-mechanical polishing, or reactive ionetching may be used to expose the diamond surfaces. The density ofdiamond powder at the surface must be a high percentage for theproperties of diamond to dictate the performance of thediamond/porcelain composite. The diamond powder may be layered on thesurface of the porcelain glass; the layering determines the maximumdensity of diamond powder obtainable on the unfired surface.

Standard formulae depending on the shape and packing structure will thendetermine the diamond powder density on the surface. For a single-sizespherical particle and a close-packed structure, the diamondcrystallites would theoretically occupy 74% of the volume with theremaining volume occupied by air. After firing, the air would bedisplaced by porcelain glass, leaving a diamond/porcelain compositestructure with maximum diamond density of 74%. The top surface of such atheoretical structure would have greater than 78% of its surface diamondexposed. Additional measures known from the composites industry could beutilized (such as mixing of powder sizes) to further increase thevolumetric diamond fraction and thus the diamond surface exposure.

As a result of performing steps S1 through S4, the diamond crystallitesconsolidate onto the workpiece surface with porcelain enamel as thebinder. Additional processing may enhance the performance of theworkpiece. Chemical etching may remove some of the porcelain enamelexposing more diamond. For example, a reactive ion etch may be used toetch the porcelain on the exposed surface of the workpiece. Mechanicalpolishing may also be used to expose more diamond. Plasma processing maybe used to chemically etch the diamond producing rounder, slicker edges.CVD processing may be used to consolidate the entire surface as diamond,e.g., using a CVD diamond applicator as disclosed in U.S. Pat. No.5,480,686 and in PCT Publication WO 96/41897 (an internationalapplication published under the Patent Cooperation Treaty that claimsbenefit of priority from U.S. application Ser. No. 08/483,982, filedJun. 7, 1995), both of which are herein incorporated by reference intheir entirety. If CVD processing is performed, the embedded diamondparticles provide seed crystals. In any case, the surface of the diamondis preferably re-hydrogenated in step S5 to restore to the diamond a lowcoefficient of friction. This is accomplished simply by polishing thediamond-tiled surface with a hydrocarbon oil-based polish.

FIGS. 2(a) through 2(e) are sectional schematics of the workpiece atvarious stages of the process described in FIG. 1. FIG. 2(a) shows asurface of porcelain enamel 1 which has been vitrified from a firingprocess. In this manner, a base substrate 2 in FIG. 2(a) is coated witha highly polished porcelain surface. FIG. 2(b) shows the workpiece afterdiamond crystallites 3 have been uniformly distributed over the surface.FIG. 2(c) shows the workpiece after firing to above the glasstemperature of the porcelain enamel 1. The diamond crystallites 3penetrate into the liquid surface of porcelain while remaining in asolid state. The liquid enamel glass wets the diamond crystallites 3.FIG. 2(d) shows the surface once the glass is cooled to roomtemperature. The diamond crystallites 3 are embedded and embossed on theporcelain enamel surface. As can be seen from FIG. 2(d) some diamondcrystallites 3 a are not attached due to excessive layering of thediamond crystallites 3. The surface is then rinsed and abrasivelyscrubbed to remove the excess un-reacted diamond crystallites 3 a. FIG.2(e) shows schematically the final workpiece after the diamond tilingprocess.

With the present invention, HPHT synthesized diamond powder (acommercial material with more than 100 tons/year produced) may be tiledonto common metal and glass surfaces using porcelain enamel as the hightemperature binder to secure the individual diamond crystallites to thesurface. Thus, the present invention combines the technology andmaturity of two distinct industrial technologies to enable theproduction of diamond-tiled durable non-stick work-pieces.

The range of substrates which could be tiled by this process is quiteextensive owing to the large number of substrates used in the porcelainenamel industry. These metal substrates include low-carbon steel,stainless steel, aluminum, cast-iron, copper, silver, and gold. Outsidethe porcelain enamel industry, whitewares and other high temperatureglasses and ceramics would be quite compatible with this process; forexample, CORNINGWARE and other china surfaces which could be used assubstrates for this process.

The range of diamond powder sizes which could be used in this process isvirtually unlimited, but the preferred range for most applications isbetween 0.01 and 50 microns (i.e., the maximum dimension of eachparticle is between 0.01 and 50 microns). If the maximum diameter of thediamond particles exceeds 5 microns, methods other than solvents may beimplemented to disperse the powder in an efficient manner. For example,aeration techniques such as those used with sandblasting grit could beused to disperse the diamond particles. Also, the diamond particlescould simply be sifted through a screen in order to disperse the diamondparticles. Diamond powder available at extremely small sizes (less than0.1 microns) may be used to implement the invention. At extremely smallsizes, diamond powder tends to cake, and thus, the powder will have tobe deflocculated before application to the workpiece surface. To avoidburning extremely fine diamond powder, care should be taken in thefiring step to avoid oxidizing the diamond powder. This can beaccomplished by either reducing the time at high temperature, firing attemperatures below 800° C., or restricting the amount of availableoxygen.

The range of porcelain enamel glasses which can be used with the presentinvention is quite extensive. The available range of porcelains islimited only by the expertise of the porcelain enamel industry indeveloping different porcelains and methods of adhering differentporcelains to base metals. Materials other than porcelain that arecapable of forming strong mechanical or chemical bonds with diamondcrystallites may also be used to bind diamond crystallites toworkpieces; for example, various glasses, whitewares, and ceramics otherthan porcelain may be used as a high temperature binder for the diamondcrystallites.

The present invention may benefit from the vast knowledge which hasaccumulated from years of industrial practice. Thus, the annealing timesand cycles will be dependent on the characteristics of the enamelselected by the porcelain industry or other pertinent industries. Forsteel-based enamel coated substrates, relatively higher temperatureenamels that permit temperatures and cycles near 850° C. may beappropriate. For various aluminum alloy-based enamel coated substrates,relatively lower temperature enamels are appropriate so as not to meltthe base substrate; such enamels will be limited to temperatures andcycles near 550 to 600° C.

Likewise, the atmospheres in the kiln will be determined by theporcelain enamel practice. Experience in the porcelain enamel industryhas shown that humidity should be controlled in the kiln to eliminatecrazing of the enamel finishes. For the practice illustrated in FIGS.2(a) through 2(e), this may not be an extreme issue because the enamelfrit has already been fired by the porcelain manufacturer producing anadherent, glass-protected surface of porcelain enamel 1.

Another sectional schematic of the workpiece and the process for forminga diamond-tiled workpiece is shown in FIGS. 3(a) through 3(e). FIG. 3(a)shows a surface of porcelain enamel coating a base substrate 2. FIG.3(b) shows the workpiece after porcelain frit 4 and diamond crystallites3 have been distributed over the porcelain enamel 1. Diamond powder maybe layered on the surface to provide the diamond crystallites 3. FIG.3(c) shows the workpiece after firing to above the glass temperature ofthe porcelain enamel 1.

The diamond crystallites 3 penetrate into the liquid surface ofporcelain enamel 1 while remaining in a solid state. The liquidporcelain enamel 1 is a fluid enamel glass that wets the diamond powderlayers. FIG. 3(d) shows the workpiece once the glass (porcelain enamel1) is cooled to room temperature. The diamond crystallites 3 areembedded and embossed on the surface of porcelain enamel 1. As can beseen from FIG. 3(d) some diamond crystallites 3 a are not attached dueto excessive layering of the diamond crystallites. In this case, thesurface is then rinsed and abrasively scrubbed to remove the excessun-reacted diamond crystallites 3 a. FIG. 3(e) is a sectional view ofthe final workpiece after the diamond-tiling process.

Another sectional schematic of the workpiece and the process for forminga diamond-tiled workpiece is shown in FIGS. 4(a) through 4(e). FIG. 4(a)shows an uncoated base substrate 2 made of an un-fired porcelainceramic. Alternatively, the base substrate 2 may be steel, a steelalloy, aluminum an aluminum alloy, or any other material on which aporcelain enamel coat can be formed.

FIG. 4(b) shows the workpiece after porcelain frit 4 and diamondcrystallites 3 have been distributed over the surface of the basesubstrate 2. Diamond powder may be layered on the surface to provide thediamond crystallites 3.

FIG. 4(c) shows the workpiece after firing to above the glasstemperature of the porcelain frit 4. The diamond crystallites 3penetrate into the liquid enamel surface while remaining in a solidstate. The fluid enamel porcelain glass wets the diamond powder layers.Preferably, the substrate 2 has a higher melting point than theporcelain frit 4. However, if a laser system or flash annealingtechnique is used to melt the porcelain frit 4, the diamond coated layermay be formed on a substrate 2 having a melting point below the meltingpoint of the frit 4.

FIG. 4(d) shows the surface once the fluid enamel porcelain glass iscooled to room temperature. The diamond crystallites are embedded andembossed on the porcelain enamel surface of the workpiece. As can beseen from FIG. 4(d) some diamond crystallites 3 a are not attached dueto excessive layering of the diamond powder. The surface of theworkpiece is then rinsed and abrasively scrubbed to remove the excessun-reacted diamond crystallites 3 a. FIG. 4(e) shows schematically thefinal workpiece after the diamond tiling process.

A propane-fired kiln may be used in the production of diamond-tiledsurfaces. Numerous books and technical reports describe the operation,specification, and construction of industrial kilns. A simple kilnconstructed from standard, commercial parts may be used to practice thepresent invention. At the base of such a kiln is a 20,000 BTU propaneburner mounted in a cast-iron stand. The cast-iron stand also provides agrate upon which the workpieces can be set. For example, a flatporcelain-coated steel pan, pre-treated with diamond powder may beplaced on the grate. Above the pan is a kiln cover which providesthermal insulation forcing a stagnant, non-convecting column of air toexist above the pan. The kiln cover is further insulated using aluminumfoil to create a high temperature oven. The burner burns astoichiometric mixture of air and propane. The burnt stream of gasdirectly heats the porcelain pan. The temperature of the pan can beobserved by viewing the pan surface by looking through the grate andbeside the propane exhaust.

Following the firing process, the work-pieces are removed from the kiln.Powder which, due to layering, does not react with the porcelain enamelis washed and abrasively scrubbed from the surface. The diamond embossedsurface is then treated with an oil-based polish to restore the surfacestate of the diamond crystallites to an hydrogenated state. An olive-oilpolish may be used to restore the hydrogenation of the diamond surfaces.Alternatively, the surface of the workpiece may be vacuum fired in orderto oxygen denude the surface before exposing the denuded surface to avariety of hydrogen sources such as atomic hydrogen, water, orhydrocarbons.

A scanning electron microscope (SEM) image of a diamond-tiled workpiecefollowing diamond consolidation using the method of this inventionreveals that the porcelain enamel wets to the diamond surface andembosses the diamond onto the porcelain surface.

The process by which the diamond crystallites are fixed on the surfaceis a complex process. However, the wetting of the diamond crystallitesby the porcelain glass is itself evidence of a reactive bond occurringbetween the diamond and the glass. Reactions between carbon and silicaare well studied reactions and are used quite prevalently today for theproduction of silicon carbide abrasives through the following reaction:

SiO₂+C(graphite)→SiC+CO(1200° C.)

Diamond, however, is more stable than graphite, and the temperaturesemployed in the present invention are much lower than the temperaturesused in the production of silicon carbide abrasives. Thus, a reactionbetween diamond and silica in the present invention is remarkable. Suchreactions are undoubtedly limited to surface reactions and can beunderstood in the light of diamond surface chemistry. Diamond as ahydrogenated surface is a very stable non-reactive surface. Literaturereports that the hydrogenated surface of a diamond gives the diamond itslow coefficient of friction. Once the surface becomes denuded, thecoefficient of friction (a measure of the surface's reactivity)increases. Oxygen terminated surfaces are also fairly reactive showing ahigh coefficient of friction. In addition to these studies, publishedwork shows the thermal stability of hydrogenated and oxygenated diamondsurfaces. It is known that at elevated temperatures hydrogen and oxygenboth desorb from the diamond surface. Hydrogen desorbs at 800° C., andoxygen (as CO) desorbs at 600° C.

The present invention utilizes high temperature surface reactions topresent to the fluid porcelain surface “reactive” diamond surfaces uponwhich the porcelain can wet. Yet, the temperatures used in the presentinvention remain below values at which there would be spontaneousreaction of the diamond and silica to form bulk SiC and CO.

A map of the surface carbon (diamond) and surface silicon (porcelain) onthe surface of a workpiece treated by the inventive method reveals thedegree of diamond exposure. One such map revealed that a diamondexposure of approximately 50% was obtained. Improvements in dispersionand firing techniques will make possible the production of surfaceshaving a diamond exposure of well over 50%. Also, mechanical andchemical techniques can be used after firing to expose diamond.

A Raman spectrum from a workpiece treated by the inventive methodreveals the effect of firing on the diamond powder. The 1332 cm⁻¹ lineof one such Raman spectrum revealed the presence of diamond and showedthat the diamond was neither dissolved by the molten porcelain, burntaway by the firing atmosphere, nor reacted into SiC.

This invention will be further illustrated by the following examples:

EXAMPLE 1

A diamond-tiled durable workpiece was produced using the processdescribed in FIG. 1 and the simple kiln described above. A porcelainenameled pan was purchased. The pan sold under the trade nameGRANITE-WARE and had a blueish porcelain enamel finish. The bowlcontained a flat bottom. The pan had an outside diameter of 28 cm and aheight of 7 cm. The interior bottom surface of the pan was 13 cm indiameter. Diamond powder screened to powder sizes less than 0.5 micronsin diameter (i.e., the diamond particles had maximum dimensions of lessthan 0.5 microns) were suspended in 120 cubic centimeters of acetone,using agitation to place the powder in suspension. The fluid along withthe suspended diamond powder was placed in a commercial spray gun madeby PREVAL. Then the pan was heated to approximately 35° C. Next, thesuspended acetone/diamond solution was sprayed onto the bottom surfaceof the pan. The acetone quickly evaporated on contact, leaving behind arelatively uniform coating of diamond powder.

The coated pan was then fired on a kiln resembling the simple kilndescribed above with the exception that no top cover was used and thepan was suspended upright above the flame of the propane burner. The panwas locally heated by the individual pilots on the burner, producinglocal hot regions on the bottom. As these hot spots approachedapproximately 800° C. the diamond powder penetrated the porcelainsurface. The pan was held at 800° C. for approximately 30 seconds. Bymoving the pan around the burner pilots, the bottom surface of theporcelain enameled pan was tiled with diamond.

The pan was cooled to room temperature, rinsed with water, andabrasively scrubbed to remove any residual diamond powder. The diamondcoverage of the treated area ranged from 50 to 70 percent. The pan wasthen rubbed with olive oil to re-hydrogenate the diamond surface. Thesurface was then wiped dry of excess oil. Scouring the pan withSCOTCHBRITE pads resulted in no visible abrasion of the diamond-tiledsurface.

Cooking tests were performed. Eggs fried on this surface (using nocooking oil or spray) readily released from the diamond-tiled surface.Even those surfaces where the eggs burned against the pan could beremoved with minimal force under water. To evaluate the stain-resistanceof the pan against dry cooking, cooking spray was applied to the surfaceand the surface was cooked until the oil burned onto the surfaceproducing a dark brown film. Continued heated of the pan merely oxidizedaway the burnt cooking spray, analogous to a self-cleaning oven interiorexcept that the stains completely atomized not leaving any cokedmaterial.

EXAMPLE 2

Electric stove top element covers are typically formed of porcelainenameled steel. A 21 cm diameter element cover was purchased with agreen enamel color finish. The electric stove top element cover wasdiamond powder coated using the same method as used in EXAMPLE 1. Thestove top element cover, pre-treated with diamond powder was then placedon the grate of a propane-fired kiln similar to the one described above.The kiln cover was placed above the kiln. Similar to EXAMPLE 1, the panwas fired to approximately 750° C. The element cover was kept atapproximately 750° C. for about 3 min. The element cover was cooled toroom temperature, had the excess powder removed, and was rehydrogenatedusing the olive oil treatment.

Visually, the element cover did not show as complete a coverage ofdiamond powder as the pan in EXAMPLE 1. Nonetheless, cooking testsshowed the surface to be stick resistant and impervious to abrasion bystandard scouring pads used on metal cookware.

EXAMPLE 3

An electric kiln was used as an alternative to the propane fired kilnused in the previous examples. The electric kiln was calibrated fortemperature and thus provided a more accurate processing environment.The isothermal nature of the commercial electric kiln provided a betterprocessing environment for practice of this invention. The electric kilnused was a Model 145E electric kiln manufactured by Allcraft Tool andSupply, Inc., Hicksville, N.Y.

Green porcelain enamel soup bowls manufactured by CINSA (soup platemodel number 22) were obtained for diamond tiling. The soup bowls werecleaned using a detergent cleaner, dried on a hot plate, and then coatedwith a dry diamond coating using the dispersion and spray practice usedin EXAMPLES 1 and 2. Various bowls were inserted into the electric kilnat progressively higher temperatures until the temperature wassufficient for reaction of the diamond powder with the porcelain enamel.It was found that at temperatures of 670° C. the dry diamond powderbonded to the porcelain enamel within two minutes. It was then possibleto re-coat with diamond powder and bond additional diamond powder ontoand in the porcelain enamel surface. After each re-coating, theporcelain surface became whiter in color and mottled.

One bowl was coated and fired 4 times at 680° C. for 2 minutes eachtime. A glass etch (sodium bifluoride) was then used to etch expose thediamond. The surface, somewhat roughened by the firing treatment, wasthen polished by hand using progressively higher grades of SiC sandpaper(320, 400, and 600 grades). The resulting polished surface, like thosein the previous examples, showed excellent non-stick properties. Afterthe initial polishing following the etch, the surface showed very littlesign of wear by the abrasive papers despite extensive abrasion. Bycomparison, the same abrasive paper on untreated bowls immediatelyshowed scuffing and scratching on the porcelain glass surface.

Additionally, the performance of the bowl to chemical etch by the sodiumbifluoride was compared to a standard porcelain enamel bowl. Thestandard bowl was visibly frosted by the glass etch solution. On theother hand, the diamond-tiled bowl made in EXAMPLE 2 was not visiblyfrosted.

EXAMPLE 4

White porcelain enameled A1 pans were obtained from Regal-Ware, Inc. Thepans were 25 cm diam pans which had been coated at Regal with ˜75 μm ofporcelain enamel.

Like EXAMPLE 3, an electric kiln Model 145 from Allcraft Tool and Supplywas used. The pans were sprayed with an aerosol solution similar to thatused in EXAMPLES 1 and 2. However, now a larger diamond powder was used.Diamond powder purchased from the Tomei Corporation was used. The powderwas graded to a 5-10 μm size powder. The aerosol solution consisted of0.250 gms of diamond powder and 150 ml of acetone. Approximately 35 mlof this solution was aerosol sprayed onto the porcelain coated A1 pan,allowing the acetone to evaporate, leaving the dry diamond powder on thesurface.

The pan was placed in the kiln, which had been pre-heated to 500° C. Thepan was then heated to 570° C. over a 12 min time frame and then rampeddown for 12 min to 500° C. before opening door to kiln and removing itfrom the oven.

The pan like previous examples was very resistant to abrasion as testedagainst various grades of SiC paper (320, 400 and 600 grades). Theresultant surfaces were showed good non-stick properties which could beimproved by buffing with a light oil coat.

Comparative Example

A light blue plate, precoated with diamond powder, was inserted into theelectric kiln used in EXAMPLE 3. The plate was kept in the electric kilnfor 15 minutes during which time the temperature in the kiln rose from750 to 950° C. After cooling, the light blue enamel on the plate haddarkened and blistered. No residual diamond powder remained on thesurface as in EXAMPLES 1, 2, and 3.

Additional Applications

In the above examples, various implements were produced in the practiceof this invention. These implements involved the formation of diamondtiled surfaces on plates. bowls, pans, and electric stove top heatingelements. Diamond tiled surfaces made in accordance with the presentinvention have many potential uses. Other such implements includecookware; grinding devices; lapping devices: polishing devices;finishing devices; plumbing fixtures including cast iron or steelfixtures having a porcelain coated surface such as bathtubs, toilets,and sinks; skis; skids; heat presses, for example, the type of heatpress used to fuse plastic or cellophane sheets in the manufacture ofplastic or cellophane bags; flatirons; boat hulls and other surfacesexposed to marine environments; electrostatic chucks for handlingsemiconductor wafers; bearings; sliding surfaces of sliding electricalcontacts; and any other application that could benefit from a durable,non-stick surface that is resilient to high temperatures and resistantto abrasion.

According to the present invention, a diamond-tiled surface can beformed on a thin porcelain layer. The resultant structure may then belaminated onto a conventional product such as a ski to provide adurable, non-stick (i.e., low coefficient of friction) ski surface.

In addition, the high diamond content of these surface coatings makesthese coatings electrically insulating and thermally conductive. Thus,according to the present invention, in a diamond tiled surface can beformed on top base metals to provide electrical insulation from andthermal conduction to the base metal. Accordingly, metal-based thermalspreaders and electrical resistance heaters can be made with the methodsof this invention. Thus, the present invention has utility in very widefields of application.

Obviously, numerous modifications and variations of the presentinvention are possible in light of the above teachings. It is thereforeto be understood that within the scope of the appended claims, theinvention may be practiced otherwise than as specifically describedherein.

What is claimed as new and desired to be secured by Letters Patent ofthe United States is:
 1. An implement comprising: a substrate; and adiamond-tiled coating layer formed on said substrate, said coating layercomprising a ceramic binder including a porcelain enamel and a pluralityof contacting diamond particles bonded to the ceramic binder to providean exposed diamond-tiled surface.
 2. The implement of claim 1, whereinthe substrate comprises: a material selected from a group consisting ofa metal and a ceramic.
 3. The implement of claim 2, wherein saidsubstrate comprises a ceramic material and said binder comprises aceramic material integrally formed with said substrate.
 4. The implementof claim 1 wherein at least 40 percent of the exposed surface isdiamond.
 5. The implement of claim 1, wherein the diamond particles havea maximum dimension less than or equal to 50 microns and greater than0.01 μm.
 6. The implement of claim 1, wherein the diamond particles havea maximum dimension less than or equal to 5 microns and greater than 1micron.
 7. The implement of claim 1, wherein the diamond particles havea maximum dimension less than or equal to 1 micron and greater than 0.01microns.
 8. The implement of claim 1, wherein the diamond particles havea maximum dimension of 0.5 microns.
 9. The implement of claim 1, whereinthe diamond particles have a maximum dimension less than or equal to0.01 microns.
 10. A product selected from a group consisting of acooking utensil, a grinding device, a lapping device, a polishingdevice, a finishing device, a plumbing fixture, a ski, a skid, a hotpress, a boat hull or other marine article, an electrostatic chuck, abearing, and a sliding electrical contact, utilizing the implementrecited in any one of the claims 1-2, 5, 7, wherein said product servesas said substrate on which the diamond tiled coating layer is formed.11. A product selected from a group consisting of a cooking utensil, agrinding device, a lapping device, a polishing device, a finishingdevice, a plumbing fixture, a ski, a skid, a hot press, a boat hull orother marine article, an electrostatic chuck, a bearing, and a slidingelectrical contact utilizing the implements recited in any one of theclaims 1-2, 5, 7, wherein the implement is laminated onto a surface ofsaid product.